TOYOTA MRP

I. INTRODUCTION:
II. PROBLEM:

The manufacturing of a car assembly requires one unit of flywheel, two unit of wheel assembly, one unit of engine lock
assembly, one unit of water pump assembly. Each unit of wheel assembly requires one unit of wheel and four units of bearings.
Each engine block assembly requires two unit of shaft and 4 units of bearings. Each unit of water pump assembly requires a
bearing of same type & price as that of engine block assembly and is designated as (E).The wheel assembly is designated here
as (C), flywheel unit is designated as(B), engine block assembly is designated as (D) and water pump assembly is designated
as (I). Wheel is designated as (F) and bearing is designated as (G), shaft is designated as (H) and engine bearing is also
designated as (E) like water pump bearing because of same type & price.

Body of Materials:

End Item A

B(1) C(2) D(1) I(1)

F(1) G(4) E(4) E(1)

H(2)

Designation: A = car assembly, B: Flywheel unit, C: wheel assembly, D: Engine block assembly,
I: Water pump assembly, F: wheel, H: shaft, G: Wheel assembly bearing, E: Engine block assembly bearing.
Demand:
Periods 1 2 3 4 5 6 7 8 9 10 11 12

Demand 200 300 500 400 600 300

of A

Component Order Quantity Lead Time Safety Projected On Scheduled

(week) Stock hand Inventory receipts

A ## 1 0 0

B 450 2 120 120 450 on week 1

C 1000 2 200 600 1000 on week 1

D 500 1 40 120 500 on week1

E 2500 1 120 120 500 on week 2

F 1000 2 120 500

G 5000 2 200 2000

H 1000 2 120 240

 I 500 2 120 120 500 on week 1

Component: A Lot size: L4L Week numbers

LT: 1 week B
Component: LLC: 0
Lot size: 450 1 2 3 4 5 6
Week 7numbers
8 9 10 11 12
Gross Requirement
LT: 2 weeks 200 300 500 400 600 300
Scheduled
SS: 120 Receipt LLC: 1 1 2 3 4 5 6 7 8 9 10 11 12
Project On hand
Gross Requirement 0 200 300 500 400 600 300
0 0 0 0 0 0 0 0 0 0 0 0
Inventory
Scheduled Receipt 450
Net Requirement 200 300 500 400 600 300
Project On hand
Planned Order 120 370 70 70 20 20 70 70 520 370 370 70 70
Inventory 200 300 500 400 600 300
Receipt
Net Requirement 0 0 430 380 80
Planned Order
Planned Order 200 300 500 400 600 300
Release 450 450 450 450
Receipt
Planned Order
450 450 450 450
Release
Component: C Lot size: 1000 Week numbers
LT: 2 weeks
SS: 200 LLC: 1 1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirement 400 600 1000 800 1200 600

Scheduled Receipt 1000

Project On hand
600 1200 600 600 600 600 800 800 800 600 600 0 0
Inventory

Net Requirement 0 400 200 400

Planned Order
1000 1000 1000
Receipt
Planned Order 1000 1000 1000
Release

Component: F Lot size: 1000 Week numbers

LT: 2 weeks
SS: 120 LLC: 2 1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirement 1000 1000 1000
Scheduled Receipt
Project On hand 500
500 500 500 500 500 500 500 500 500 500 500 500
Inventory
Net Requirement 500 500 500
Planned Order
1000 1000 1000
Receipt
Planned Order
1000 1000 1000
Release

Component: G Lot size: 5000 Week numbers

LT: 2 weeks
SS: 200 LLC: 2 1 2 3 4 5 6 7 8 9 10 11 12
Gross Requirement 4000 4000 4000
Scheduled Receipt
Project On hand 2000 2000 3000 3000 4000 4000 4000 0 0 0 0 0 0
Inventory
Net Requirement 2000 1000
Planned Order 5000 5000
Receipt
Planned Order
Release 5000 5000